Cutting oil treatment apparatus

ABSTRACT

A method and apparatus for the biological purification of cutting oil, such as used in metal machining apparatus, is disclosed. The invention herein provides a suitable environment for cultured aerobic bacteria. These beneficial bacteria act to break down the hazardous organic waste products of anaerobic bacteria and eliminate rank odors. The cutting oil is aerated to encourage the proliferation of the aerobic bacteria, and to discourage the proliferation of the unwanted anaerobic bacteria.

This is a divisional of application of U.S. Ser. No. 08/042,120, filedApr. 2, 1993, now U.S. Pat. No. 5,314,620.

TECHNICAL FIELD

This invention relates to methods and materials for cleaning cutting oilused in the machining of metal parts.

BACKGROUND OF THE INVENTION

Cutting oil is a generic term for that class of oils which are used inmetal machining operations. Cutting oil generally comprises one or moremineral oil, chlorinated or sulfurized mineral oil, fatty oil, ormixtures thereof. The cutting oil is provided at the cutting surfacewhere a metal-shaping bit is used to modify a metal workpiece. Cuttingoil provides a lubricating film between the cutting bit and theworkpiece, thus keeping the cutting area cooled. The continuous flow ofcutting oil acts to retain metal shards or flakes formed during thecutting process, and to carry these flakes away from the cuttingsurface. The cutting oil can also contain anti-corrosion agents,emulsifiers, anti-bacterial agents, and the like.

One example of a machining apparatus 110 is shown in FIG. 1. A workpiece112 (shown in cross section) is supported below a cutting bit 114. Theworkpiece 112 and the cutting bit 114 are moved relative to one another,either by motion controls such as the handle means 116 shown, or bycomputer controls (not shown). Generally, motion controls providerelative movement along each of the x, y and z axis.

A reservoir of cutting oil is maintained within the body of themachining apparatus 110. The cutting oil is pumped to a nozzle 118located proximal to the cutting surface. The cutting oil is sprayed overthe workpiece 112 and the cutting bit 114. A drain system (not shown)returns the cutting oil to the reservoir.

The presence of metal flakes in the cutting oil has traditionallylimited the effective use life of cutting oils. However, a variety ofmethods have been developed to enhance the life of the cutting oil byfiltering the oil, either before it is sent to the cutting oilreservoir, while it is held within the reservoir, or as it is brought tothe cutting surface. Generally, the larger flakes are removed byfiltration or straining. The smaller metal flakes can be removed byskimming or other processes. Cutting oil can be filtered by theprocesses described in U.S. Pat. No. 4,325,663, for example.

Cutting oil can become contaminated by anaerobic bacteria. The presenceof anaerobic bacteria in the cutting oil reservoir causes rank andrancid odors, limiting the useful life of the cutting oil for aestheticreasons. The presence of the anaerobic bacteria can also provide asource of irritation or contagion for the humans who must come intocontact with the cutting oil in either liquid or volatilized form.

SUMMARY OF THE INVENTION

A method and apparatus for the biological purification of cutting oil,such as used in metal machining apparatus, is disclosed. The inventionherein provides beneficial, aerobic bacteria which act to break down thehazardous organic waste products of anaerobic bacteria. The cutting oilis aerated to encourage the proliferation of the seeded aerobicbacteria, and to discourage the proliferation of unwanted anaerobicbacteria.

Specifically, a method for the biological purification of cutting oilcomprises the steps of aerating cutting oil; introducing aerobicnitrifying bacteria into the aerated cutting oil; and supporting theaerobic proliferation of the introduced bacteria.

The aerobic bacteria are preferably introduced in a medium whichincludes an inorganic base material upon which the cultured aerobicbacteria are supported. Alternatively, an oil-based culture ofappropriate bacteria can be introduced into the cutting oil. When anoil-based culture is introduced, the oil base should not interfere withthe use of the cutting oil.

The aerobic bacteria are innocuous to humans. Generally, the aerobicbacteria includes at least one of a nitrobacter sp. or a pseudomonas sp.Aeration is preferably done before the introduction of the bacteriaculture, and continued subsequent to the introduction of the culture, topromote the growth of the beneficial bacteria.

In accordance with the invention herein, an improved apparatus formachining metal is also presented. The improved metal machiningapparatus includes, within a cutting oil reservoir, an aeration sourceand a cultured aerobic bacteria source.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a machining apparatus of the prior art.

FIG. 2 shows a partial cross-section view of a metal machining apparatusof this invention, including a cutting oil recirculating system, anaeration system, and a source for cultured aerobic bacteria.

FIG. 3 shows an alternate partial cross-section view of a metalmachining apparatus of this invention.

The Figures are drawn for clarity and are not drawn to scale. Similarnumbers refer to similar structures throughout the Figures.

DISCLOSURE OF THE INVENTION INCLUDING BEST MODE

FIG. 2 shows a cross-sectional representation of a machining apparatusof this invention. A workpiece (not shown) is supported below a cuttingbit 214. During operation of the machining apparatus, the workpiece andthe cutting bit 214 are moved relative to one another, as describedabove. A variety of cutting bits 214 are known to the art, and thespecific cutting bit used will vary with the metal being machined andthe desired shape of the final product.

Cutting oil is a generic term for that class of oils which are used inmetal machining operations. Cutting oil generally comprises one or moremineral oil, chlorinated or sulfurized mineral oil, fatty oil, ormixtures thereof. The cutting oil can also contain anti-corrosionagents, emulsifiers, and the like. It is preferred that the cutting oilused in the subject invention not contain any anti-bacterial agentswhich would interfere with the proliferation of aerobic bacteria.

Cutting oil is provided at the surface where a metal-shaping bit orblade is used to modify a metal workpiece. Devices which use cutting oilinclude lathes, cold-saws, milling machines, and the like. Cutting oilprovides a lubricating film between the cutting device and theworkpiece, thus keeping the cutting area cooled. The continuous flow ofcutting oil acts to retain metal shards or flakes formed during thecutting process, and to carry these flakes away from the cuttingsurface. The cutting oil is removed from the cutting area by a retrievalconduit 220. This retrieval conduit 220 is adapted to deliver usedcutting oil from the cutting area to a cutting oil reservoir 222. Withinthe cutting oil reservoir 222 is a recirculating pump 224 which returnscutting oil to the nozzle 218, continuing the cycle. One or more cuttingoil reservoir 222 is generally located within the body of the machiningapparatus 210.

In accordance with the invention herein, an aeration system 226 islocated at least partially within the cutting oil reservoir 222. Theaeration system 226 acts to increase the oxygenation of cutting oil inthe cutting oil reservoir. The aeration system 226 is run constantly,whether or not the machining apparatus is being run. Failure of theaeration system 226 can cause die-off of the aerobic bacteria within thesystem. If the aeration system 226 has been disconnected for 12 hours ormore, it is generally recommended that the reservoir 222 system bere-seeded with a new bacteria starter culture 232.

If a standard machining apparatus is to be retro-fitted to include anaeration system, as shown in FIG. 2, an aeration system including an aircompressor (not shown) and air tubing 228 is generally used. Aircompressors are generally designed to function in a clean, dryenvironment. Therefore, it is generally convenient to locate the aircompressor outside the body of the machining apparatus 210. A variety ofappropriate air compressors are known. Care must generally be takenduring installation and use of the air compressor to ensure that cuttingoil cannot escape the reservoir through or along the air tubing. Ifpossible, the air compressor is placed above the level of the cuttingoil in the reservoir to avoid siphoning in the event of power failure.Preferably, an anti-siphon valve is positioned along the air tubing 228.

Air tubing 228 is connected at one end to the air compressor, and at theother end to an air diffuser or airstone. Air tubing 228 is commerciallyavailable in varying rigidity, diameters and lengths. Generally, therigidity, diameter and length of the air tube will be dictated by thespecific air compressor used and its proximity to the fluid reservoir.

If flexible air tubing 228 is threaded through curves having a smallradius, a rigid pinch protection collar should be provided to avoidcrimping of the tubing. In one embodiment, hooks or other such devicesare provided to secure the air tubing 228 along its course from the aircompressor to the airstone or air diffuser. By securing the air tubing228 in place, inadvertent crimping of the tubing can be minimized oravoided.

The air tubing 228 is generally connected to one or more air diffusersor airstones 230. When more than one air diffuser or airstone is used, a"T" connector or splitter can be used to provide multiple tubingconnections between a single air compressor and multiple airstone units.It is generally preferred that the air diffuser or airstone 230 devicebe weighted or otherwise secured to remain at or near the bottom of thereservoir.

A wide variety of stone, ceramic, and polymeric airstones 230 arecommercially available. Over time, airstones may become clogged. Theairstone should be kept clean according to the manufacturer'sinstructions, and replaced regularly.

Aerobic and anaerobic bacteria are normally present as contaminants incutting oil. The initiation of aeration will generally start the processof encouraging the proliferation of aerobic bacteria and discouragingthe proliferation of anaerobic bacteria. The process of colonization thepreferred bacteria can be dramatically shortened by seeding the cuttingoil with a starter culture 232 of the desired aerobic bacteria. For bestresults, this starter culture is introduced into the cutting oilconcurrent with, or slightly after, the start of the aeration process.

The temperature of the cutting oil reservoir will generally be aboutroom temperature. Even while cutting oil is being used (and thereforeheated) at the cutting surface, the aeration (room temperature air) willact to stabilize the temperature within the reservoir. Generally,however, the temperature should be kept with the range of about 15° C.to about 37° C.

The pH of the cutting oil will generally remain in the range of about 6to about 8.5.

If the temperature, pH, or other variable causes the bacteria die offand rank odors result, it is recommended that the cutting oil bediscarded and fresh cutting oil, with an appropriate bacterial starterculture, be placed into the system.

Generally, the aerobic bacteria which are encouraged for proliferationin the cutting oil aeration system are those bacteria which facilitatean aerobic decomposition of the decomposable organic materials suspendedin the cutting oil. Nitrifying bacteria, such as nitrobacter sp. andpseudomonas sp., are especially appropriate.

The bacteria starter culture 232 must be compatible with the cuttingoil, and must not interfere with the function of the cutting oil. Thebacteria starter culture 232 is therefore preferably provided on aninorganic matrix which is insoluble in cutting oil. The inorganic matrixincludes cultured aerobic bacteria on surfaces upon and within thematrix. A suitable matrix material is perlite. When a particulate matrixis used, it is generally preferable to contain the particulate materialwithin a flow-through structure. For example, a rigid or flexibleplastic outer structure having a plurality of holes therethrough canenclose a non-woven nylon filter membrane. These materials can behot-stamped to fuse them into a suitable container for a particulateperlite matrix.

In an alternate embodiment (not shown), an oil-based culture medium(including the starter culture) can be provided. In a less preferredembodiment, the starter culture is provided in an aqueous base.

Aerobic bacteria can be cultured from native bacteria in soil, or can becultured from an aerobic cutting oil environment. Alternatively, acommercially prepared bacterial starter can be used. A variety ofsuitable aerobic bacteria cultures are commercially available. The "Bio520" starter culture, available from Harvey Universal, Inc. (Torrance,Calif.) is especially suitable. "Hi-Clean Σ" from Sankai Chemical Co.(Tokyo, Japan) can also be used.

Preferably when a solid matrix starter culture 232 is used, it isweighted to remain at the bottom of the reservoir 222 while permittingeasy circulation of the aerated cutting oil. When a solid matrix is usedto provide the starter culture, it can be attached to a string or otherhandling means for ease of retrieval from the reservoir 222. In thepictured embodiment, a string 234 is connected to a hook 236 to provideeasy access to the starer culture.

FIG. 3 shows an embodiment in which a single airstone 330 providesaeration for the reservoir 322. Rigid air tubing 328 connects the singleairstone 330 to the air compressor (not shown). As pictured, theretrieval conduit 320 preferably provides returning cutting oil at apoint distant from the recirculating pump 324. This helps maintain agood circulatory flow, in which cutting oil is brought across theairstone 330 and the starter culture 332.

While the invention has been described in connection with severalexemplary embodiments, it will be understood that many modificationswill be apparent to those of ordinary skill in the art in light of theabove disclosure. Such modifications may include using substitutematerials, smaller or greater dimensions, varying the number andplacement of starter culture media, using a variety of differentaeration devices, and so forth, to achieve substantially the sameresults in substantially the same way. Reference to the following claimsshould be made to determine the scope of the invention.

I claim:
 1. An improved apparatus for machining metal, said apparatuscomprising:(a) cutting oil delivery nozzle, said nozzle being adapted toprovide cutting oil to a cutting area; (b) a cutting area including abit for machining metal; (c) a cutting oil retrieval means to removeused cutting oil from the cutting area and return it to a cutting oilreservoir; (d) a cutting oil reservoir; (e) an aeration means locatedwithin the cutting oil reservoir, said aeration means acting to increasethe oxygenation of cutting oil in the cutting oil reservoir; and (e) acultured nitrifying bacteria source located in said cutting oilreservoir.
 2. An apparatus of claim 1 wherein the bacteria sourceincludes at least one selected from the group consisting of culturednitrobacter sp., pseudomonas sp., and mixtures thereof.
 3. An apparatusof claim 1 wherein the bacteria source further comprises an inorganicbase material containing said cultured bacteria supported thereupon. 4.An apparatus of claim 1 wherein the bacteria source further comprisescultured bacteria in an oil base.
 5. An apparatus of claim 1 wherein theaeration means comprises at least one from the group consisting of anair diffuser and an airstone.
 6. An apparatus of claim 1 wherein saidcultured bacteria source comprises an inorganic matrix supportingcultured aerobic bacteria, said matrix being contained within astructure which permits the flow of cutting oil therethrough.
 7. Anapparatus of claim 6 wherein said flow-through bacteria supportstructure is removably attached to said apparatus for machining metal.8. An apparatus of claim 6 wherein said flow-through bacteria supportstructure is weighted to remain at the bottom of said cutting oilreservoir.